Constructible utensils

ABSTRACT

A system and method for meeting market demand for better constructible utensils. A deformable sheet defines a handle and an operational element in which one or more scores, both straight and curved, are cooperatively provided on the sheet. The one or more scores enable deformation of the handle and/or operational element(s) to convert the structure into a strong, sturdy, and functional implement sufficient to meet the required application.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/214,993 filed 16 Mar. 2014 which claims benefit of U.S. patentapplication No. 61/786,434 filed 15 Mar. 2013, the contents of which arehereby expressly incorporated in its entirety by reference thereto.

FIELD OF THE INVENTION

The present invention relates generally to constructible utensils, andmore specifically, but not exclusively, to constructible utensils forfoodstuff.

BACKGROUND OF THE INVENTION

The subject matter discussed in the background section should not beassumed to be prior art merely as a result of its mention in thebackground section. Similarly, a problem mentioned in the backgroundsection or associated with the subject matter of the background sectionshould not be assumed to have been previously recognized in the priorart. The subject matter in the background section merely representsdifferent approaches, which in and of themselves may also be inventions.

As market acceptance for constructible utensils increases, alternativedesigns and implementations offer retailers and consumers more choicesto further increase market acceptance (including functions, cost, andease of use).

Sustainability, recyclability, compostability are becoming increasinglyimportant to retailers and consumers. However, not everyone uses theterms correctly—marketers sometimes use these indiscriminately andvaguely, often to the frustration of environmentally and sociallyconscious manufacturers, retailers, and users who desire more accuracy.Increasingly standards for sustainability are being developed and usedto help retailers and consumers avoid “green washing” for the productsthat they buy and use.

For true ecological friendliness, materials and products meet specific,ever-evolving standards and requirements. The “green” world employs aspecial lexicon, particularly for words such as degradable,biodegradable, recyclable, sustainable, and compostable.

Degradable plastics are oil based and break down through chemicalreactions rather than the activity of micro-organisms, so they candegrade in an anaerobic environment into water, CO2, biomass, and traceelements. For example, the term “biodegradable” by itself does not meanmuch when biodegradable plastics and some types of biodegradable spoonsinclude products that may take 100's to 1,000's of years to degrade.Since “biodegradable” specifies NO time limits, for the purposes ofcomposting and sustainability “biodegradable” is a meaningless term.

To be considered compostable, plastic material must break down within180 days in a commercial compost facility. Biodegradable plastic has notime limit. According to the American Society for Testing & Materials(e.g., ASTM D6400-2004 “Standard Specification for CompostablePlastics,” ASTM International, West Conshohocken, Pa., 2003, DOI:10.1520/D6400-04, hereby expressly incorporated by reference thereto inits entirety for all purposes), for plastic to be considered ascompostable, it must be able to break down into carbon dioxide, water,and biomass at the same rate as paper. It also needs to look likecompost, should not produce any toxic material and should be able tosupport plant life. Compostable items are made from plant materials suchas corn, potato, cellulose, soy, sugar, and the like.

Another important ASTM standard is ASTM D6868-2011 “StandardSpecification for Labeling of End Items that Incorporate Plastics andPolymers as Coatings or Additives with Paper and Other SubstratesDesigned to be Aerobically Composted in Municipal or IndustrialFacilities,” ASTM International, West Conshohocken, Pa., 2003, DOI:10.1520/D6868-11, also hereby expressly incorporated by referencethereto in its entirety for all purposes. This specification establishesthe requirements for labeling of materials and products (includingpackaging), wherein a biodegradable plastic film or coating is attached(either through lamination or extrusion directly onto the paper) tocompostable substrates and the entire product or package is designed tobe composted in municipal and industrial aerobic composting facilitieswithin 180 days.

The term compostable until recently was subject to some ambiguity.Certifications and representations of compostability most oftenreference commercial/municipal composting facilities that preciselycontrol the environment (e.g., temperature) and microbes (e.g., periodicinfusion of appropriate quantities of the appropriate microbes). Fewbio-based utensils are certified compostable, and most include varyingamounts of plant based starch and petroleum and take over the required180 days or more to compost under the best of conditions. Homecomposting is rarely an option for these materials. Some “biodegradable”products like Taterware may take years—compost facilities eitherdisallow all bioplastic utensils or pick them out of the compost at theend of the composting process.

Consumers have become increasingly skeptical of certain claims as to thevarious “green” attributes of various manufacturers and products sincethe introduction of “biodegradable plastics” in the late 1980s. Althoughtouted as “environmentally friendly,” many so-called biodegradableplastic products did not compost as implied. And yet manufacturers ofthese products were able to make claims of biodegradable because noscientifically based definitions, test methods and standards existed.Promulgation, adoption, and use of the ASTM specifications, definitions,and tests mentioned above provide a standard by which products andmaterials may be evaluated. To this end, there are organizations thatprovide certification of conformance to one or more of these standardsas appropriate. For example, the Biodegradable Products Institute, 331West 57th Street, Suite 415, New York, N.Y. 10019 has created a“compostable logo” which is designed to help remove some of theconfusion for consumers. The Compostable logo builds credibility andrecognition for products that meet the ASTM D6400 and/or D6868 standardsso consumers, composters, regulators, and others can be assured that theproduct will compost as expected.

As consumers, composters, waste scavengers, regulators, and otherscontinue to develop the technologies and processes for efficientlyhandling and sorting consumer waste, consumers and businesses(collectively purchasers) are on the front line and make importantdecisions. The decisions include selection, use, and, disposal ofproducts. Selection is important, based upon a purchaser's understandingthe degradability of the product and, as noted above, can be improved bycertifications informing a purchaser of the attributes of a product.Additionally, based upon experience and history that the purchaser haswith particular products, the purchaser may be influenced towardsselection or use. This is important with utensils designed forfoodstuffs—how the utensil feels in the mouth of the user is important.Coatings, sharp edges, dimensions, sturdiness, and the like all play apart in selection and use.

After selection and use, the user decides on, or initiates/influences,post-use handling. It is not always clear to the user whether a productis recyclable, compostable, or should be included as trash. Users areoften confronted with a multitude of bins with disposal options. Forsome products, it is problematic to select the wrong receptacle. And thepropriety is not just a simple matter of knowing the characteristics ofthe product—one sometimes needs to know the specifics of the processingused by the disposal/recycling/scavenging entity to match a product tothe right process capabilities of recycler/scavenger. This can beoverwhelming to a user and can produce undesirable outcomes for theintended “green” behavior. For example, many petroleum-based utensilsare recyclable, and most bio-based plastics are NOT recyclable. Mostusers cannot readily distinguish one composition from another to allowthem to properly manage the product, even if they were current as to therecycling capabilities of the local processor.

As varying compositions of consumer-products are introduced, the userbecomes increasingly confused as to which the product that they want toprocess is recyclable and how to quickly and error-free sort the variousproducts. Some “green” conferences have recycling advisors stationed atwaste collecting areas to help educate users.

There are many instances where single-use products are currently usedfor tasting and consuming foodstuffs. Mostly these products are madefrom a plastic or a bio-material that is not, or insufficiently,compostable and easily bio-degradable. These products typically comepreformed into the recommended configuration for use by the user.

To compound the problem, there are many venues in which utensils aresingle-use (e.g., foodstuff tasting/dispensing utensils orsingle-serving disposable utensils). Not only is the sorting/processingproblem multiplied by the sheer volume of these products usedworld-wide, they also use up too many resources. This is because theseproducts also have the further undesirable characteristic of attemptingto emulate conventional multi-use utensils in their construction andarrangement which results in poor packing density. Manufacturers,distributors, and retailers are increasingly concerned about cubeutilization (amount of product that can be shipped/stored in a specificcubic volume). The less efficient the cube utilization, particularly ascompared to alternative products, the more costly it becomes to ship andwarehouse.

It is not always the case that a utensil design scales well as seen inmany “mini” tasting spoons that yield a bowl that is often too small andshallow for properly supporting, dispensing, and consuming adequateserving sizes of a range of foodstuff. Both the retailer and theend-user can become frustrated by this. Sometimes the design is furtheraltered after scaling which results in more material and often worsecube utilization. Not only can these products be inefficient, suchproducts often take up an unnecessarily large amount of space in thepreformed configurations while being inefficient and costing more. It isunderstandable as preformed configurations in consumer-familiar designsis believed to maximize strength while minimizing user complexities.

Compounding the problem further, bioplastics use more material in theirconstruction because they do not have the same material properties(e.g., tensile strength of bio-material versus stainless steel versusconventional petroleum-based plastic). There are many disadvantages toconventional tasting/single-use utensils, particularly to thoseattempting to be truly environmentally-friendly.

Currently there are several “green” factors that can be independentlyevaluated which include: recyclable, renewable, compostable, andsustainable, and usage of material efficiency and cube utilizationefficiency for volume and weight). A product and processes that measurefavorably against these factors while being friendly, convenient,effective, and efficient for the retailer, consumer and waste processoris preferred.

What is needed is a system and method for meeting market demand forbetter constructible utensils.

BRIEF SUMMARY OF THE INVENTION

Disclosed is a system and method for meeting market demand for betterconstructible utensils. The following summary of the invention isprovided to facilitate an understanding of some of technical featuresrelated to constructible utensils, particularly to those used as aspoonlid or single-use tasters, and is not intended to be a fulldescription of the present invention. A full appreciation of the variousaspects of the invention can be gained by taking the entirespecification, claims, drawings, and abstract as a whole. The presentinvention is applicable to other constructible utensils as well asconstructible paperboard structures other than utensils.

A deformable sheet defines a handle and an operational element in whichone or more scores, both straight and curved, are cooperatively providedon the sheet. The one or more scores enable deformation of the handleand/or operational element(s) to convert the structure into a strong,sturdy, and functional implement sufficient to meet the requiredapplication. In the preferred embodiment, the unconstructed utensil isprovided on a planar sheet made of the requisite material (i.e., anappropriately green/sustainable material) that may be processed toenhance function (e.g., coated with environmentally appropriatematerial) to resist premature degradation during use (e.g., amoisture-barrier) or it may be manufactured of a moisture-barriermaterial (e.g., calcium carbonate), collectively a coating, or inherentcharacteristic or other moisture protection system is referred to asmoisture-barrier property. Thus, quantities of the unconstructedmaterial achieve a far greater packing density as compared topre-constructed utensils, which saves money on shipping and storagebecause of the smaller cube size. For many applications, the handle andoperational elements are minimalist in material cost while maximizingstructural strength and user-experience consistent with the intended useall the while having a smaller carbon footprint.

The handle, typically with a curved score that defines a folding axis,is operated by bringing portions closer together out of the plane (e.g.,folding or otherwise deforming) the handle along the one or more handlescores. This folding induces a responsive distortion/deformation of theoperational element to create the desired functional element. The curvedscore(s), in cooperation with the structural organization andcomposition, produce a constructed utensil that meets or exceedsperformance of conventional preformed disposable/single-use utensils.This provides a superior option over conventional constructed utensilsbecause the user gains the advantage of an improved single-useapplication while the utensil is eco-friendly as it has a minimalistdesign that is effective and capable of being made compostable and/orrecyclable with recyclable, sustainable, renewable resources. Theseconstructible utensils may be particularly configured for specificapplications, including tasting, stirring, spreading, consumingharder/firmer foodstuffs, “fork-like” utensil, and the like.

Manufacturers have an option of configuring the base material, theperiphery boundary, the placement and orientation of scores, and anycoating to customize the final design in a wide variety of ways. Asfurther explained herein, the user-constructible utensils includetasters, spreaders, stirrers that can have appropriately shaped handlesand operational elements (e.g., bowls for a tasting spoon) that have thedesired capacity, shape, and mouth-feel. Some bowls may have a deepconfiguration for more capacity while others may be shallower andsturdier to serve dense/hard foodstuff (e.g., ice cream). Thefundamental teachings herein are adaptable to a wide-variety ofuser-constructible utensils for a wide-variety of tasks. In some cases,the utensil doubles as a dispensing mechanism, in lieu of a cup, whichis particularly important for applications that use a utensil along witha cup and/or plate/napkin, cracker, or the like, providing valuablecost-savings.

In some embodiments, such as a dispensing and tasting implement at afood show of the like, the base material and scores are arranged andconfigured so that a deformed handle (e.g., folded) maintains asufficiently useful fold after being released from the folder to retainthe desired configuration of the operational end. For example for atasting spoon, several utensils may be configured including folding thehandle to produce the bowl. The folded utensils are set on a worksurface and a product is placed into each of the bowls. Consumers maysimply pick up a utensil and sample the product without any otherapparatus. This allows for one-handed sampling, as opposed to cup andspoon, which is ideal for consumers having their hands full withproducts, information, containers, kids, and the like. In many of thepreferred embodiments, lateral edges of the planar apparatus are foldedup to produce a handle and bowl, often leaving a planar medial portionof the handle and bowl that provide a stable platform for adding,dispensing, and presenting the product to the prospective consumers.Most tasting spoons could not be arrayed and used in this fashion asthey are not large enough or stable enough and do not have theupward-extending handle portions to allow them to be easily grasped. Inthis way, packing density for dispensing and presenting is improved andretailers/users may select from a middle of the array with greatlyreduced risk of touching or otherwise contaminating foodstuff in otherutensils.

Particularly for those applications that include a disposable plate,cup, napkin for dispensing and a utensil to consume, the versatility ofthe implementations of the present invention in combining thesefunctions further saves costs and reduces environmental impact in thepre-consumer and post-consumer costs of such scenarios.

As noted above, many existing single use solutions attempt to emulateconventional utensils. While this is desirable to simplify training anduse of the utensils, the products are often wasteful of material (and insome cases extra unneeded material results in the material/producttaking up excessive space which further adds to costs in transportationand storage and is “anti-green”), particularly for applications wherethe utensil may be used for a few seconds. Considering that some currentutensils are used for just a few seconds and may exist in landfills forcenturies points out one of the many problems addressed and mitigated byembodiments of the present invention.

The preferred implementations of the present invention provide a greatlyreduced carbon footprint due to several factors including use of a newminimalist design (rather than scaling of previous utensils) that bothuses less material and reduces unnecessary material and use ofenvironmentally friendly materials. This is true even in cases where thematerial is misprocessed by the consumer after use. For example, if acompostable EcoTensil® brand utensil ends up in a landfill it will havean increased chance to be partially-to-substantially degraded by thetime it gets to a landfill where under normal conditions it would notdegrade. (Modern landfill designs attempt to minimize any degradation ofall materials by removing oxygen and other requirements forbiodegradation/composting). Because the product has minimal material useand quickly degrades, the product lends itself to interstitial locationamong the nooks and crannies of other more rigid elements of thelandfill, which effectively removes its contribution to the landfillvolume.

Reduction in material used in the designs helps to maximize an amount ofpre-disposal degradation that occurs which is advantageous no matterwhether the consumer selected the correct disposal option. Theadvantages of minimal construction are magnified when also consideringthe production, shipment, storage, use, and disposal volumes. Thereduced eco-footprint appears all along the lifespan of the product andsavings and advantages are compounded when considering the entirelifecycle.

A constructible utensil, such as for a taster for example, includes adeformable generally planar rigid paperboard sheet defining a body, thebody including a handle element having a fold axis and a bowl elementcoupled to the handle element wherein the handle element is generallyelongate and rectilinear and includes a length generally parallel to thefold axis that is at least two times greater than a width generallyperpendicular to the fold axis; a first curved score disposed on thebody and extending from a first point on the bowl element proximate afirst edge of the bowl element to a second point on the handle elementproximate the fold axis; and a second curved score disposed on the bodyand extending from a third point on the bowl element proximate a secondedge of the bowl element towards the second point; wherein the scoresare generally concave with respect to the fold axis; and wherein thebody is configured with an arrangement of the scores such that a foldingof the body about the fold axis introduces a bowl in the bowl element bydistortion of the bowl element along the curved scores.

A constructible utensil, such as for a stirrer for example, includes adeformable generally planar rigid sheet material defining a body, thebody including a handle element having a fold axis and a bowl elementcoupled to the handle element at a transition area wherein the handleelement is generally elongate and includes a length generally parallelto the fold axis that is at least ten times greater than a first widthgenerally perpendicular to the fold axis; a first score disposed on thebody and extending from a first point on the bowl element to a secondpoint on the handle element proximate the fold axis and crossing thetransition area; and a second score disposed on the body and extendingfrom a third point towards the second point, wherein the third point isdisposed on the bowl element; wherein the scores are curved andgenerally concave with respect to the fold axis and generallysymmetrical about the fold axis; wherein the body is configured witharrangement of the scores such that a folding of the body about the foldaxis introduces a bowl in the bowl element.

A constructible utensil, such as for a spreader for example, includes adeformable generally planar rigid paperboard sheet defining a body, thebody including a handle element having a fold path and a spreaderelement coupled to the handle element wherein the spreader element isgenerally asymmetrically elongate and includes a first lateral edgegenerally straight and parallel to the fold path and a second lateraledge generally convexly curved with respect to the fold path andconverging to the first lateral edge; a first score disposed on the bodyand extending from a first point on the spreader element to a secondpoint on the handle element proximate the fold path; and a second scoredisposed on the body and extending from a third point towards the secondpoint; wherein the body is configured with arrangement of the scoressuch that a folding of the body about the fold path introduces a bowl inthe spreader element.

A constructible utensil includes a deformable generally planar rigidpaperboard sheet defining a generally elongate and rectilinear bodyhaving a long axis extending from a proximal end to a distal end and ashort axis generally perpendicular to the long axis with the bodyincluding a fold axis extending along the long axis and the bodyincluding a length generally parallel to the fold axis that is at leasttwo times greater than a width generally parallel to the short axis; afirst curved score disposed on the body and convex with respect to thefold axis, the first curved score extending from a first point on thebody near a first lateral edge of the body at the distal end of the bodyto a second point on the body proximate the fold axis, wherein the firstpoint is greater than 75% of the length from the proximal end andwherein the second point within 33% of the length from the proximal end;and a second curved score, symmetric about the fold axis to the firstcurved score and disposed on the body, the second curved score extendingfrom a third point on the body near a second lateral edge of the body atthe distal end to the second point; wherein the body is configured witharrangement of the scores such that a folding of the body about the foldaxis introduces a bowl in the body at the distal end by distortion inthe body along the scores.

A method of manufacturing a constructible utensil includes a) forming agenerally elongate and rectilinear body from a deformable generallyplanar rigid paperboard sheet, the body having a long axis extendingfrom a proximal end to a distal end and a short axis generallyperpendicular to the long axis with the body including a fold axisextending along the long axis and the body including a length generallyparallel to the fold axis that is at least two times greater than awidth generally parallel to the short axis; b) disposing a first curvedscore on the body, the first curved score convex with respect to thefold axis, the first curved score extending from a first point on thebody near a first lateral edge of the body at the distal end of the bodyto a second point on the body proximate the fold axis, wherein the firstpoint is greater than 75% of the length from the proximal end andwherein the second point within 33% of the length from the proximal end;and c) disposing a second curved score, symmetric about the fold axis tothe first curved score, on the body, the second curved score extendingfrom a third point on the body near a second lateral edge of the body atthe distal end to the second point; wherein the body is configured witharrangement of the scores such that a folding of the body about the foldaxis introduces a bowl in the body at the distal end by distortion inthe body along the scores.

A method of constructing a utensil includes a) folding a generallyelongate and rectilinear body about a fold axis, the body constructedfrom a deformable generally planar rigid paperboard sheet, the bodyhaving a long axis extending from a proximal end to a distal end and ashort axis generally perpendicular to the long axis with the bodyincluding the fold axis extending along the long axis and the bodyincluding a length generally parallel to the fold axis that is at leasttwo times greater than a width generally parallel to the short axis andthe body including a pair of curved scores symmetrically disposed on thebody, the pair of curved scores convex with respect to the fold axis,the curved scores extending from a pair of points on the body nearopposing lateral edges of the body at the distal end of the body andeach converging to a convergence point on the body proximate the foldaxis, wherein the pair of points are greater than 75% of the length fromthe proximal end and wherein the convergence point is within 33% of thelength from the proximal end; and b) inducing a bowl in the distal endresponsive to the folding step a) by distorting the body along the pairof scores as the body is folded.

A system for serving a foodstuff includes a worksurface; and a pluralityof user-constructible utensils constructed into a plurality ofshape-retaining utensils with each the shape-retaining utensil includinga bowl-element supporting a portion of the foodstuff and having a pairof lateral edges folded upwards and retained folded without adhesive dueto a configuration of construction materials used in a manufacture ofthe plurality of user-constructible utensils and wherein the pluralityof constructed utensils are arrayed on the worksurface with the upwardpair of lateral edges useable as a handle to remove a correspondingutensil and foodstuff from the worksurface.

Any of the embodiments described herein may be used alone or togetherwith one another in any combination. Inventions encompassed within thisspecification may also include embodiments that are only partiallymentioned or alluded to or are not mentioned or alluded to at all inthis brief summary or in the abstract. Although various embodiments ofthe invention may have been motivated by various deficiencies with theprior art, which may be discussed or alluded to in one or more places inthe specification, the embodiments of the invention do not necessarilyaddress any of these deficiencies. In other words, different embodimentsof the invention may address different deficiencies that may bediscussed in the specification. Some embodiments may only partiallyaddress some deficiencies or just one deficiency that may be discussedin the specification, and some embodiments may not address any of thesedeficiencies.

Other features, benefits, and advantages of the present invention willbe apparent upon a review of the present disclosure, including thespecification, drawings, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, in which like reference numerals refer toidentical or functionally-similar elements throughout the separate viewsand which are incorporated in and form a part of the specification,further illustrate the present invention and, together with the detaileddescription of the invention, serve to explain the principles of thepresent invention.

FIG. 1 illustrates a constructible utensil including an exteriorperimeter and a score pattern configured to produce a constructiblespork;

FIG. 2 illustrates a constructible taster utensil including an exteriorperimeter and a score pattern configured to produce a constructibletaster having a widened operative element;

FIG. 3 illustrates both an unconstructed and constructed constructibleutensil including an exterior perimeter and a score pattern configuredto produce a constructible utensil having a backstop;

FIG. 4 illustrates a constructible taster utensil including aperpendicular score for length-shortening folding; and

FIG. 5 illustrates a construction sequence for a constructible utensilincluding an exterior perimeter and a score pattern configured toproduce a novel spoon lid utensil.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention provide a system and method formeeting market demand for better constructible utensils. The followingdescription is presented to enable one of ordinary skill in the art tomake and use the invention and is provided in the context of a patentapplication and its requirements.

Various modifications to the preferred embodiment and the genericprinciples and features described herein will be readily apparent tothose skilled in the art. Thus, the present invention is not intended tobe limited to the embodiment shown but is to be accorded the widestscope consistent with the principles and features described herein.

It should be noted that the figures include specific shapes, paths, andarrangements of scores used to facilitate formation of three dimensionalbowls as a part of a body is folded. The scores have been illustrated toaccurately present representative suitable score paths for theparticular utensil type and application, particularly with respect tolocation, arrangement, and placement.

The constructible utensils disclosed herein are generally representativeof a wide range of constructible utensils, some of which have beenillustrated and described in related patents and patent applications.These related patents and patent applications include U.S. Pat. No.8,210,381, D646,529, and D651,480, and U.S. patent application Ser. Nos.13/357,557, 61/699,808, 61/699,787, 61/712,610, 13/797,446, concurrentlyfiled application entitled MATRIX FOR CONSTRUCTIBLE UTENSIL, U.S.application Ser. No. ______ (Attorney Docket 20226-7013), andconcurrently filed application entitled SPOONWRAP FOR CONTAINER, U.S.application Ser. No. ______ (Attorney Docket 20226-7014), all of whichare hereby expressly incorporated by reference thereto in theirentireties for all purposes.

In some cases, because a preferred embodiment includes environmentallyfriendly materials which often include paper and paper-like substances.For a utensil, it is the case that the foodstuff may have a significantmoisture content. To enhance longevity in terms of preserving structuralintegrity and strength over the serving/portion size, moistureresistance is important in some implementations. Such utensils may beprocessed to enhance function (e.g., coated with environmentallyappropriate material) to resist premature degradation during use (e.g.,a moisture-barrier) or it may be manufactured of a moisture-barriermaterial (e.g., calcium carbonate or the like), collectively a coating,or inherent characteristic or other moisture protection system isreferred to as moisture-barrier property.

Some preferred embodiments include a paperboard sheet material. In someof the descriptions, there are certain score lines that are specificallyset forth to be close to, but spaced away from, an edge of a body orbody element of a constructible utensil. For some materials, thesescores break down fiber used in the body and could increase moistureabsorption. Spacing a terminating end of these score lines away from thephysical edge improves moisture absorption resistance.

The preferred embodiments use sustainable tree-based wood fibers due toimproved material properties. In some applications, and as additionalmaterials are developed, other materials (such as shorter fibers fromother plants or mineral-based substrates) may be used in lieu oftree-based wood fibers. Additionally, the preferred embodiments describeimplementations that include multiple curved scores, including multiplecurved scores that “bend” inwardly towards each other. Someimplementations may include other configurations, including a singlecurved implementation that produces a bowl when folded along this score.

Some of the disclosed embodiments include configuration changes to abasic constructible single-use taster.

The constructible taster includes a generally “bullet” shaped perimeterhaving a longitudinal axis about which the constructible taster isgenerally symmetric. The perimeter is about 1.25 inches wide and about3.125 inches long (the “bullet” shaped perimeter including a generallyrectangular body that is about 1.25 inches×about 2.5625 inches and asemi-disk at one end of the rectangle having a radius of about 0.5625inches). A handle portion is joined to a functional end with handleportion including a short handle score extending along the longitudinalaxis and joining a pair of curved scores extending from lateral edges ofthe functional end located at a distal end (e.g., opposite of the handleportion at a proximal end). In some implementations the handle score maybe omitted, its function provided by an extension of one or more of thecurved scores extending towards the proximal end from the distal end.Folding/deforming the proximal end along the handle score (or handlescore substitute) induces the deformation of the functional end aboutthe one or more curved scores to create a three-dimensional structure(generally described as arched or bowl-shaped) which addsstrength/rigidity and function, such as retaining low-viscosityfoodstuff.

The tasters are generally small and the constructible taster isparticularly configured to reduce material use while providing efficientoperation. A size and shape of a bowl formed in the constructible tasterat the distal end is determined, again, by the arrangement of the scoreswith respect to the body and its structures. For example, in thepreferred embodiment, the scores are close to lateral edges of the bodynear the distal end (without reaching the edge to improve mouth feel byreducing sharp edges) and converge to a central fold axis near theproximal end and produce the desired bowl shape. The scores are gentleand convex with respect to the fold axis and curve over almost theentire length of the rectilinear body and do not meet until very closeto the edge. For purposes of this application in the context of ataster, the scores converge within 33% of the length of the body elementfrom the handle end and most preferably within 10% of the length fromthe handle end. At the other end, the scores reach near the lateraledges at points greater than 50% of the length and most preferably atpoints greater than 75%.

Included with the constructible taster are informational indicia (e.g.,specifically positioned dots) that identify a preferred location forsqueezing/deforming the handle portion. (E.g., bend to touch dots whichrecreate the desired deformation in the handle to help optimizeformation of the functional element.) Preferably these indicia areplaced near where the scores converge. In this case, towards theproximal end of the body, so that the body gradually distorts alongscores generally over the entire length.

In some embodiments it will be desirable to provide some type ofmechanism to maintain the lateral edges of the body (e.g., near theindicia) in a generally folded arrangement to preserve a desired minimumcapacity/shape to the formed bowl (and to maintain those lateral edgesextending upwards to be easily grasped to permit The constructibletaster to be picked up from a work surface, especially with the bowlshape retained). The material selection of the body and the depth andnature of the formation of the scores are one way to provide for aretaining force resisting unfolding when a folding force is removed. Inother embodiments, some type of tacky adhesive or interconnecting tabsmay be used to hold the lateral edges together and the body in thefolded mode.

The incorporated patents and patent applications describe alternatescore patterns and perimeter shapes for the constructible taster, andother constructible utensils described herein. Those alternates may becombined with the basic taster and further modified as described hereinin keeping with the present invention.

FIG. 1 illustrates a constructible utensil including an exteriorperimeter and a score pattern configured to produce a constructiblespork. The constructible spork of FIG. 1 is a modification of theconstructible taster and includes a bowl-producing score pattern withthe forward free curvilinear edge including 2 tines, with 2-5 tinespossible with different perimeter notching. The tines of theconstructible spork helps to spear and catch noodles, salads, fruitsalads and the like.

FIG. 2 illustrates a constructible taster utensil including an exteriorperimeter and a score pattern configured to produce a constructibletaster having a widened operative element. The constructible tasterutensil of FIG. 2 is a modification of the constructible taster andincludes a widened spoon end (i.e., the functional end). Theconstructible taster utensil of FIG. 2 aids the consumer and can help toreduce material usage during manufacturing.

FIG. 3 illustrates both an unconstructed and constructed constructibleutensil including an exterior perimeter and a score pattern configuredto produce a constructible utensil having a backstop. The constructibletaster utensil of FIG. 3 is a modification of the constructible tasterand includes a score pattern having backstop scores at the end of thehandle portion. When needed or desired, a consumer is able to fold upthe backstop along the backstop scores to create a dam that preventscontents (e.g., liquids) from spilling off the back end of the handle.The backstop scores include a pair of linear scores extending from acommon point on the longitudinal axis back towards rear corners of thehandle portion. Those scores, combined with a longitudinal scoreextending from an edge of the handle towards the functional end (whichis sometimes present in certain implementation of the constructibletaster) cooperate with the pair of linear scores to selectively producethe independently operable backstop. The backstop is independent fromthe bowl-producing scoring pattern as the user may or may not use thebackstop with a folded and constructed utensil.

FIG. 4 illustrates a constructible taster utensil including aperpendicular score for length-shortening folding. The constructibletaster utensil of FIG. 4 is a modification of the constructible tasterand includes a perpendicular (e.g., to the longitudinal axis and/or thefold axis) fold to allow the constructible taster utensil to be lengthcollapsible to fit on small packages. Even though the constructibletaster is typically configured to be very short, there are applicationsin which it is desired to have a shortened constructible taster, such asinclusion in certain small footprint foodstuff containers (e.g., foodsamples and the like). Also the constructible taster utensil frequentlyneeds to be longer than the side or top of a container so it can reachinto the container and still have length for the consumer to hold thehandle end.

The perpendicular fold enables a pre-constructed length of constructibletaster utensil to shortened for packaging. Depending upon a location,the folded length may be shortened anywhere from 50% to 75% of theunfolded length.

FIG. 5 illustrates a construction sequence for a constructible utensilincluding an exterior perimeter and a score pattern configured toproduce a novel spoon lid utensil. The incorporated patent documentsinclude description and illustrations of several different spoon lids.The products can have a handle portion having a perimeter matching thecontainer opening/lid shape and a functional extension that is foldablyattached to the handle portion. Unfolding the functional extension andfolding the handle portion creates an extended bowl-portion suitable forreaching into the container and consuming the foodstuff containedwithin. Those solutions offer the advantage of a small pre-constructedfootprint with the ability to have a greater length when constructed. Insome instances the folding process increases unit costs due to thefolding step and addition of any releasable adhesive securing thefunctional extension in the folded configuration to be ready for use.And as compared to the constructible utensil illustrated in FIG. 5, sucha system includes “extra” material that is not used by the embodiment ofFIG. 5.

The constructible utensil of FIG. 5 includes a paperboard (or othersuitable foundation material) blank shaped to match the intended packinglocation (which for this implementation is under a lid to help maintainthe constructible utensil in a clean and sanitary condition but otherlocations are possible). The perimeter can thus be shaped to match thecontainer mounting/attachment location, frequently it is circular suchas for a yogurt container. Other perimeter shapes are possible and asvaried as possible opening shapes.

The desired perimeter shape is cut and a number of interior scores andcuts are formed within the blank. The cuts form a bullet-shapedfunctional portion that is hingedly fixed to the interior of the blank.A pair of lateral scores connecting ends of the cut to the exterior formhinges that allow the bullet-shaped functional portion to be displacedfrom the plane of the blank and rotated 180 degrees about the hinginglateral scores so the functional portion now extends past theopening-shaped perimeter. Scores on the functional include a typicalcurved score pattern that are symmetric about a fold axis. That foldaxis is aligned with a score on the interior portion of the blank andthus allows the structure to be easily folded about the fold axis toproduce a constructed utensil for use with the container. Theconstructible utensil thus saves material and folding costs as comparedto the reference spoonlid system described herein.

The system and methods above has been described in general terms as anaid to understanding details of preferred embodiments of the presentinvention. In the description herein, numerous specific details areprovided, such as examples of components and/or methods, to provide athorough understanding of embodiments of the present invention. Somefeatures and benefits of the present invention are realized in suchmodes and are not required in every case. One skilled in the relevantart will recognize, however, that an embodiment of the invention can bepracticed without one or more of the specific details, or with otherapparatus, systems, assemblies, methods, components, materials, parts,and/or the like. In other instances, well-known structures, materials,or operations are not specifically shown or described in detail to avoidobscuring aspects of embodiments of the present invention.

Reference throughout this specification to “one embodiment”, “anembodiment”, or “a specific embodiment” means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention and notnecessarily in all embodiments. Thus, respective appearances of thephrases “in one embodiment”, “in an embodiment”, or “in a specificembodiment” in various places throughout this specification are notnecessarily referring to the same embodiment. Furthermore, theparticular features, structures, or characteristics of any specificembodiment of the present invention may be combined in any suitablemanner with one or more other embodiments. It is to be understood thatother variations and modifications of the embodiments of the presentinvention described and illustrated herein are possible in light of theteachings herein and are to be considered as part of the spirit andscope of the present invention.

It will also be appreciated that one or more of the elements depicted inthe drawings/figures can also be implemented in a more separated orintegrated manner, or even removed or rendered as inoperable in certaincases, as is useful in accordance with a particular application.

Additionally, any signal arrows in the drawings/Figures should beconsidered only as exemplary, and not limiting, unless otherwisespecifically noted. Furthermore, the term “or” as used herein isgenerally intended to mean “and/or” unless otherwise indicated.Combinations of components or steps will also be considered as beingnoted, where terminology is foreseen as rendering the ability toseparate or combine is unclear.

As used in the description herein and throughout the claims that follow,“a”, “an”, and “the” includes plural references unless the contextclearly dictates otherwise. Also, as used in the description herein andthroughout the claims that follow, the meaning of “in” includes “in” and“on” unless the context clearly dictates otherwise.

The foregoing description of illustrated embodiments of the presentinvention, including what is described in the Abstract, is not intendedto be exhaustive or to limit the invention to the precise formsdisclosed herein. While specific embodiments of, and examples for, theinvention are described herein for illustrative purposes only, variousequivalent modifications are possible within the spirit and scope of thepresent invention, as those skilled in the relevant art will recognizeand appreciate. As indicated, these modifications may be made to thepresent invention in light of the foregoing description of illustratedembodiments of the present invention and are to be included within thespirit and scope of the present invention.

Thus, while the present invention has been described herein withreference to particular embodiments thereof, a latitude of modification,various changes and substitutions are intended in the foregoingdisclosures, and it will be appreciated that in some instances somefeatures of embodiments of the invention will be employed without acorresponding use of other features without departing from the scope andspirit of the invention as set forth. Therefore, many modifications maybe made to adapt a particular situation or material to the essentialscope and spirit of the present invention. It is intended that theinvention not be limited to the particular terms used in followingclaims and/or to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include any and all embodiments and equivalents falling within thescope of the appended claims. Thus, the scope of the invention is to bedetermined solely by the appended claims.

What is claimed as new and desired to be protected by Letters Patent ofthe United States is:
 1. The apparatus substantially as disclosedherein.
 2. The method substantially as disclosed herein.